Container with outfolded flanges



United States Patent Lewis C. Houston [72] lnventor Port St. Joe, Florida 21 Appl. No. 764,424

[22] Filed Oct. 2, 1968 [45] Patented Oct. 27, 1970 [73] Assignee St. Joe Paper Company Jacksonville, Florida a corporation of Florida 54] CONTAINER WITH OUTFOLDED FLANGES 15 Claims, 10 Drawing Figs.

Assistant ExaminerSteven E. Lipman Attorneys-George H. Baldwin and Arthur G. Yeager ABSTRACT: A container formed from an integral blank and having a body portion including end wall panels and flanges longer than the side wall as measured between the side wall side edges substantially continuously joined along the upper side wall edge and along at least a part of the upper edges of the end wall panels which are joined to respective side walls. Each flange is folded outwardly and downwardly at the upper edges and lie against the outer surfaces of the side wall and attached end wall panels, such flange being continuous adjacent the wall angle formed between the side wall and end wall panels. A flange is joined along the upper edge of each end wall, each flange being folded downwardly at the end wall upper edge and extending over the upper edges of adjacent end wall panels and over the portions of the side wall flanges which are connected to the adjacent end wall panels. All of the flanges form a perimeter covering for the upper edges of the side walls and end walls and end wall panels to inhibit moisture from entering the upper edges thereof.

Patented Oct. 27, 1970 Sheet 2 or 3 INVENTOR. [ea/15 0. Hal/5Z0 32, a1 ATTORNEY Patented Oct. 27, 1970 3,536,249

' Sheet 3 of 3 FIG. IO

I INVENTOR. 13 laws 0. flax/.5101? i ywnm ATTORNEY CONTAINER WITH OUTFOLDED FLANGES BACKGROUND OF THE INVENTION Field of the Invention This invention relates to containers and more particularly to flbreboard corrugated containers of the type adapted for use SUMMARY OF THE INVENTION This invention relates to a corrugated container including a body portion having a rectangular bottom,.upstanding end walls respectively hingedly joined along the bottom end edges, and upstanding side walls respectively hingedly joined along the bottom side edges. An end wall panel is respectively hingedly joined to each side wall side edge. The side walls and end wall panels and end walls include upper edges constituting the body portion upper edge and flange means are provided peripherally around the body upper edge to coversame thereby preventing moisture from entering same. The flange means includes flanges having exposed outer surfaces which are continuous from the inner wall surface of each wall and outwardly and downwardly of the outer wall surface of each wall. The flange means comprises a respective flange joined to the upper edge of the side wall and the upper edges of the attached end wall panels outwardly folded and continuous around the wall angle between the side wall and adjacent end wall panel. The flange means further comprises a respective flange joined to the upper edge of each end wall outwardly folded over the portions of the adjacent'flanges attached to the end wall panels and folded over the upper edges of the adjacent end wall panels. The cover portion includes upwardlyv extending edge means for selectively lockingly engaging beneath the lower free edges of the portions of the flanges.

The flange means further includes connecting means between the flanges and the attached end walls whichrare formed by a pair of spaced and parallel fold lines containing intermittent perforations for folding the flanges into a position closely adjacent the ends of the container body.

The invention is directed to an integral blank for folding into a container body having a rectangular bottom with oppositely disposed side edges and oppositely disposed end edges extending laterally of the side edges. The blank also includes a pair of rectangular side walls having their lower edges connected by fold lines to respective bottom side edges and a pair of rectangular end walls having their lower edges connected by fold lines to respective bottom end edges. Each end wall includes an elongated flange means extending outwardly from the upper edge of the end wall. The blank further includes a pair of rectangular end wall panels having side edges with one side edge of each end wall panels being connected to a respective side edge of the side wall by a fold line. A pair of flange means are provided by the blank respectively connected by fold lines to the upper edges of each side wall throughout the length thereof and connected to the upper edges of the end wall panels attached to respective side walls. The pair of flange means are adapted to extend fromand downwardly of theside wall upper edges and of the end wall panel upper edges and being continuous. adjacent the wall angle formed between the side wall and end wall-panels. The flange means of each end wall is adapted to extend from and downwardly of the end wall upper edge and the upper edges of the adjacent end wall panels.

The flangemeans of each end wall includes a flungeextending throughoutthe length of the and upper edge and connecting means formed by a pair of spaced and parallel fold lines for attaching each flange to respective end wall upper edge, such fold lines containing intermittent perforations to permit folding of respective flanges to closely position same adjacent the end of the erected container body. Each of the pair of flange means include a flange extending throughout the length of the side, upper edge and a pair of partial flanges, each partial flange being connected by a fold line to the upper edge of respective end wall panel. Such fold lines are substantially in alignment with the upper edge of the adjacent side wall. Each partial flange is also connected by a fold line to the adjacent side wall flange, such fold line being substantially in alignment with the respective side edge of adjacent side wall. The partial flange as measured between its fold line connection with the side flange and theside free edge thereof and as measured parallel to the end wall panel upper edge, and the end wall panel as measured between the end wall panel side edges and as measured parallel to the end wall panel upper edge together are generally equal to or less than the distance between the side edges of the end wall whereby one of the partial flanges lie in the same plane as the end wall panel carrying the other Another particular object is the provision of an improved rectangular container body having single thickness sides, substantially triple thickness ends, double thickness upper edge portions of the sides and quadruple thickness upper edge portions of the ends.

A speciflc'object is the provision of an integral blank for folding into a rectangular container body which is prescored and precut with a minimum of waste and simple to erect.

BRIEF DESCRIPTION OF THE DRAWINGS The novel features which are believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings, in which:

FIG. 1 is a plan view of a container body blank in accord with this invention;

FIG. 2 is a plan view of a container cover blank;

FIG. 3 is an isometric view of the container body erected from the blank of FIGQl;

FIG. 4 is an isometric view of the container cover erected from the blank of FIG. 2;

FIG. 5 is a cross-sectional view taken along line 5-5 of FIG. 3 with the cover closingly engaged the body;

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 3 with the cover closingly engaging the body;

FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 3 with the cover closingly engaging the body;

FIG. 8 is a cross-sectional view taken along line 8-8 of FIG.

3; and 7 FIG; 9 is a cross-sectional view taken along line 9-9 of FIG. 3: and,

FIG. lll'isra cross-sectional view taken along line 10-10 of FIG. 4.,

DESCRlFTlON OF THE PREFERRED EMBODIMENT Referring now more particularly to FIG. 1, the integral blank 20 is shown in its completed form after it has been cut from a sheet of single wall corrugated board in the desired peripheral outline with a minimum waste thereof. Blank 20 has been prescored, as indicated by broken lines, and precut, as indicated by full lines to permit proper folding and manipulation into a container body. Blank 20 comprises a rectangular bottom 21, rectangular side walls 22 and 23 extending respectively from opposite elongated bottom side edges or fold lines 24 and 25, and end walls 26 and 27 extending respectively from opposite bottom end edges or fold lines 28 and 29. Rectangular end wall panels 30 and 31 are connected respectively to side wall side edges or fold lines 32 and 33 and similar end wall panels 34 and 35 are connected to side wall 23 by fold lines 36 and 37. Flange means 40 and 41 are respectively connected to the upper edges 42 and 43 of each side wall 22 and 23 by fold lines throughout the length thereof and are connected to the upper'edges 44 and 45 of the attached end wall panels 30 and 31 and the upper edges 46 and 47 of the attached end wall panels 34 and 35. Flange means 40 is seen to include a side wall flange 50 attached along the upper edge 42 of side wall 22 and a pair of partial flanges 51 and 52 being connected by fold lines 53 and 54 to the upper edges 44 and 45 of end wall panels 30 and 31. Flanges 51 and 52 are also connected by fold lines 55 and 56 to side wall flange 50. As seen in FIG. 1 fold lines 53 and 54 are substantially in alignment with the upper edge or fold line 42 of side wall 22 and are also in alignment with the upper edges 44 and 45 of end wall panels 30 and 31. Fold lines 55 and 56 are respectively in substantial alignment with fold lines 32 and 33 connecting between side wall 22 and respective end wall panels 30 and 31 which form the respective wall angles of the container body when erected. lt is to be understood that flange means 41 includes substantially identical components as those previously described in connection with flange means 40.

Each end wall 26 and 27 includes a flange means 60 extending outwardly from the upper edge 61 of end walls 26 and 27. Each of the flange means 60 includes a flange 62 extending throughout the length of the end wall upper edge 61 and connecting means 63 formed by a pair of spaced and parallel fold lines 64 and 65 for attaching flange 62 to the upper edge 61 of end walls 26 and 27. The spacing of the fold lines 64 and 65 is sufficient to permit nesting of a plurality of thicknesses of corrugated fibreboard therebetween after the flanges are bent over the end wall panels and the partial flange as described more fully in connection with FIGS. and 6.

Fold lines 64 and 65 perferably include intermittent perforations through both liners and the corrugating medium from which the blank is made to permit the proper folding of flanges 62 outwardly and downwardly to lie externally of the outer end wall panels 30 and 34 and end wall panels 31 and 35 It is to be understood that other techniques of accomplishing substantially similar results may be employed in lieu thereof, for example, a five point double walled score may be used which provided two scores on one face of the corrugated sheet materials and three scored on the other face thereof. Score lines 55 and 56 are provided between partial flanges 51 and 52 and flange 40 to permit such flanges to properly bend around the corners formed at the upper end portion of the adjacent side and end walls of the container body as hereinafter more specifically described.

The containerblank further includes hand cutouts 70 in each of the end wall panels 30, 31, 34 and 35 with the hand cutouts of end walls 30 and 34 becoming aligned with the proper folding and erection of the blank 20 into the container body and similarly hand cutouts 70 of end wall panes 31 and 35 coincide to provide a sufficient handhold for the-erected container body. Drainage openings 71 are provided spacedly through end wall 26 and 27 which align with vthe drainage notches 72 in respective end wall panels 30, 31, 34 and 35 so that water which may enter through the opened container body may drain out therethrough.

The cover blank is depicted in FIG. 2 having been properly cut and scored from a piece of single wall corrugated board to provide the desired peripheral outline. Blank 80 comprises a rectangular top panel 81 defined by side fold lines 82 and 83 and end fold lines 84 and 85. Side panels or walls 86 and87 extend longitudinally of fold lines 82 and 83 and terminate at each end in an end locking flap or ear 90. Each locking ear 90 is hingedly attached to a respective end of the cover side walls 86 and 87 by a fold line 91 which extends parallel to the end wall fold lines 84 and 85 by which respective end walls 92 and 93 are attached to the top panel 81. End walls 92 and 93 have outer longitudinal edges defined by double score lines 95 and 96 which are parallel to fold lines 84 and 85. Inner end wall portions 97 and 98 respectively engage an ear 90 with such ears being located between inner end wall portion 97 and 98 and the respective end walls 92 and 93 when the cover blank is erected into the cover as shown in FIG. 4. An car 100 is respectively connected to each of end walls 92 and 93 by perforated score lines 101 and 102 generally medially of end walls 92 and 93 and spaced generally medially between score lines 84 and 96. When the blank 80 is erected, ears 100 are folded on the double perforated score lines 101 and 102 with such ears lying against respective end walls 92 and 93 and substantially in the same plane as ears 90, as seen in FIG. 4. Ears 100 provide a filler function between adjacent ears 90 when the cover is erected thus providing generally continuous surfaces respectively contacting the outer surfaces, including surface 110, of end flanges 60 of the erected body portion 105, as seen in FIG. 3.

The parts of the container body 105 as shown in F IG. 3 are identified with identical reference characters as employed in connection with the respective corresponding parts of the blank 20 as shown in FIG. 1. The container body 105 comprises a single thickness bottom 21 joined to upstanding single thickness side walls 22 and 23 and to upstanding inner end walls 26 and 27. A pair of inner end wall panels 30 and 31 are connected by wall angle fold lines, such as line 32, to side wall 22, it being understood that outer er..l wall panels 34 and 35 are similarly connected to side wall 23.

The upper edge 43 of side wall 23 includes an outwardly and downwardly directed flange means 41 which is constituted by flange 50 and flanges 51 and 52 which are connected to end wall panels 34 and 35. Flange means 40 is connected to the upper edge 42 of side wall 22 which is constituted by an identical flange 50 and flanges 51 and 52. As seen in FIG. 3, flange 50 and flanges 51 and 52 are continuous adjacent the wall angle formed between side walls 23 and the attached end wall panels 34 and 35 with flange 50 lying against the outer surface 107 of side wall 23 and flanges 51 and 52 lying against the outer surfaces, including surface 108 of end wall panels 34 and 35 End wall 27 and end wall panel 31 sandwich therebetween end wall panel 35 throughout a portion of its length. The end wall of the container is formed substantially by a triple thickness of corrugated fibreboard with the aligned handholds 70 cutout from each of end panels 31 and 35 providing a double thickness handhold for the container body. The length of the end wall panel, for example, end wall panel 31, as measured between its free edge 1 15 and the wall angle fold 33, and the length of ear 52, as measured between its free edge 114 and fold 56, is generally equal to or less than the distance between the side edges and 121 of end wall 27 whereby flange 52 lies in the same plane as end wall panel 31. The openings 71 in the end walls 26 and 27 respectively align with drainage notches 72 in respective end wall panels 30, 34, 31 and 35.

The flange means 60 which are attached to end walls 26 and 27 are folded outwardly and downwardly along the parallel fold lines 64 and 65 with the end wall panels 30, 34, 31 and 35 together with the attached flanges 51, 52 being sandwiched between flange means 60 and the respective inner end walls 26 and 27 The ends of the container body are thus erected and maintained in the erected position by fastening means in the form of staples 112 which extend through and fasten end wall panels 31 and 35 together prior to end wall 27 being folded to its upstanding position as shown. Flange means 60 is then folded outwardly and downwardly to its operative position and staples 113 are then inserted through flange means 60,.end wall panels 31 and 35 and through end wall 27, while staple 116 extends through flange means 60, flange 56, end wall panel 35 and end wall 27, and staple-117 extends through flange means 60, flange 52, end wall panel 31 and end wall 27.

The container body 105 includes flange means generally designated 125 peripherally around the body portion upper edge 126 to cover same thereby preventing moisture from entering the upper edge of the body. Flange means 125 includes the previously described flanges 50 and 62 which have exposed outer surfaces 128 and 110 that are continuous from the inner wall surfaces 129 and 130 of respective walls 22 and 23 and walls 26 and 27. The flange 50 is continuous around the wall angles which are integrally connected with flanges 51 and 52, flanges 51 and 52 being tucked beneath respective flange means 60 which are attached to end walls 26 and 27 with the flange means 60 extending over the respective upper exposed edges 44, 45, 46 and 47 of end wall panels 30, 31, 34 and 35.

The erected cover is generally depicted in FIG. 4 by numeral 134 with the parts of the cover being'identified with identical reference characters as employed in connection with the respective corresponding parts of cover blank 80 as shown in FIG. 2. The cover 134 includes a top panel 81 with upstanding side walls 86 and 87, and upstanding end walls 92 and 93, each upstanding wall being attached to top panel 81. Flaps 90 are tucked between respective end walls 92, 93 and respective flanges 97 and 98 and staples 138 extend through respective side walls and flaps 90 and flanges 97 and 98 to maintain the cover in its erected position. Each of flanges 97 and 98 include an upwardly extending edge 135 when the cover is upturned into its proper position covering container body 105, so that such locking edges 135 engage beneath the downturned edges 140 of flanges 62 and edges 141 and 142 of respective flanges 52, as more specifically described in connection with FIGS. 5 and 6. The ears 100 are bent over on their fold lines 101 and 102 and are generally frictionally held by edge 150 contacting the bottom surface 151 of top panel 81. Locking flaps 90 and ear 100 adjacent each end wall 92 and 93 are seen to provide generally continuous surfaces which contact the outer surfaces 110 of respective flanges 62 when the cover 134 closingly engages the container body 105.

The corrugations in body blank are indicated by arrow A while arrow B depicts the corrugations in the cover blank 80. In the erected or set-up condition of the container as shown in FIGS. 3 and 4, the corrugations A in the side walls 22 and 23 and end wall panels 30, 31, 34 and 35 are vertical to allow the container 105 to have a high stacking strength. The corrugations in the end walls 26 and 27 are horizontal thereby providing the container 105 with side to side compression strength. With the upper edge of the container 105 being covered by the flange means, previously described, moisture in the form of water spray is inhibited from entering the normally exposed corrugations at the upper ends of the side wall and/or end walls of the container. Thus, the container is particularly suitable for use in hydrocooling in which the perishables are sprayed with cooling water after packaging within the container prior to enclosing same with the cover.

FIG. 5 depicts the manner in which the cover 134 closing engages the container body 105. The upturned flange 97 slightly bend outwardly due to the resiliency of the fibreboard being bent around locking cars 90 and due to the staples 138 partially crushing the corrugated fibreboard adjacent the connecting fold lines 95 and 96 between the flange 97 and end wall 93. The upwardly facing locking edge 135 of flange 97 engages beneath downwardly facing edge 140 of flange 62 and downwardly facing .edge 141 of flange 52. It is to be understood that if edge 140 is below edge 141, edge 135 will engage only edge 140, and if edge 141 is below edge 140, edge will engage only edge 141 adjacent the corners of the container.

In FIG. 6, the upwardly facing edge 135 is seen to engage beneath downwardly extending edge adjacent the midportion of the end walls or generally throughout the horizontal dimension of the outermost end wallpanel 31 between flanges FIGS. 7, 8,9 and 10 illustrate details of the fabrication and construction of the container body 105 and cover 134, such details having been adequately described hereinbefore.

While only a certain preferred embodiment of this invention has been shown and described by way of illustration, many modifications will occur to those skilled in the art and it is intended that all such modifications be included within the true spirit and scope of this invention.

lclaim:

1. In a container comprising a body portion including a rectangular bottom having side and end edges, upstanding end walls hingedly joined along said bottom end edges, upstanding side walls hingedly joined along said bottom side edges, each said side wall having opposite side edges, an end wall panel hingedly joined to each said side wall side edge, a flange longer than said side wall as measured between said side wall side edges substantially continuously joined along the upper edge of each said side wall and along at least a part of the upper edges of said end wall panels joined to respective said side wall, each said flange being folded outwardly and downwardly at said upper edges and lying against the outer surfaces of said side wall and attached end wall panels, each said flange being continuous adjacent the wall angle formed between said side wall and end wall panels, flange means joined along the upper edge of each said end wall, each said flange means being folded downwardly at said end wall upper edge and extending over the upper edges of the adjacent said end wall panels and over the portions of said side wall flanges which are connected to the adjacent said end wall panels.

2. In the container as defined in claim 1 wherein each said flange means includes a flange extending throughout the length of said end upper edge and connecting means formed by a pair of spaced and parallel fold lines for attaching each said flange to respective said end wall upper edge. 7

3. In the container as defined in claim 2 wherein said pair of fold lines each include intermittent perforations for folding respective said flange into a position closely adjacent the end of the container body.

4. In the container as defined in claim 1 wherein each said flange means includes a flange folded outwardly and,

downwardly at said upper edges of said end walls and lying against the outer surfaces of one said end wall panel and said portions of said side wall flanges attached to the adjacent said end wall panels.

5. In the container as defined in claim 1 wherein said body is formed of corrugated fibreboard, said flange and flange means forming a perimeter covering for said upper edges of said side walls and end walls and end wall panels.

6. In the container as defined in claim 1 further comprising a cover portion, upwardly extending edge means attached to said cover portion for selectively lockingly engaging beneath the lower free edges of said portions of said side wall flanges.

7. In the container as defined in claim 6 wherein said each flange means includes a flange extending throughout the length of said end upper edge and having a lower free edge spaced downwardly from its fold line connection with said end wall, said edge means further selectively lockingly engaging beneath said lower free edge of said end wall flange.

8. In a corrugated container comprising a body portion including a rectangular bottom having side and end edges, upstanding end wall hingedly joined along said bottom end edges, upstanding side walls hingedly joined along said bottom side edges, each said side wall having opposite side edges, an end wall panel hingedly joined to each said side wall side edge, said side walls and end wall panels and end walls having upper edges constituting the body portion upper edge, flange means peripherally around said body upper edge to cover same thereby preventing moisture from entering said upper edges, said flange means including flanges having exposed outer surfaces which are continuous from the inner wall surface of each wall and outwardly and downwardly of the outer wall surface of each wall, said flange means comprising a respective flange joined to the upper edge of said sidewall and the upper edges of the attached said end wall panels outwardly folded and continuous around the wall angle between said side wall and adjacent said end wall panel, said flange means further comprising a respective flange joined to said upper edge of each said end wall outwardly folded over the portions of the adjacent said flanges attached to said end wall panels and folded over said upper edges of said adjacent end wall panels.

9. In the container as defined in claim 8 further comprising a cover portion, upwardly extending edge means attached to said cover portion for selectively lockingly engaging beneath the lower free edges ofsaid portions of said flanges.

10. An integral blank for folding into a container body comprising a rectangular bottom having oppositely disposed side edges and oppositely disposed end edges extending laterally of said side edges, a pair of rectangular side walls having their lower edges connected by fold lines to respective said bottom side edges, a pair of rectangular end walls having their lower edges connected by fold lines to respective said bottom end edges, each said end wall having an elongated outwardly foldable flange means extending outwardly from the upper edge of said end wall, a pair of rectangular end wall panels having side edges with one said side edge of each said end wall panel being connected to a respective side edge of said side wall by a fold line, each said end wall panel having a free edge adjacent and parallel respective side edges of said end walls, a pair of outwardly foldable flange means respectively connected by fold lines to the upper edges of each said side wall throughout the length thereof and connected to the upper edges of said end wall panels attached to respective said side walls, said pair of flange means being adapted to extend outwardly from and downwardly of said side wall upper edges and of said end wall panel upper edges and being continuous adjacent the wall angle formed between said side wall and end wall panels, said flange means of each said end wall being adapted to extend outwardly from and downwardly of said end wall upper edge and said upper edges of the adjacent said end wall panels.

11. In the integral blank as defined in claim 10 wherein said blank is formed of corrugated fibreboard, said flange means and said pair of flange means forming a perimeter covering for said upper edges of said side walls and end walls and end wall panels of the erected container body.

12. In the integral blank as defined in claim 10 wherein said flange means of each said outwardly foldable end wall includes a flange extending throughout the length of said end upper edge and connecting means formed by a pair of spaced and parallel fold lines for attaching each said flange to respective said end wall upper edge.

13. In the integral blank as defined in claim 12 wherein said pair of spaced and parallel fold lines include intermittent perforations to permit folding of respective said flange to closely position same adjacent the end of the erected container body.

14. in the integral blank as defined in claim 10 wherein each said pair of outwardly foldable flange means includes a flange extending throughout the length of said side wall upper edge and a pair of partial flanges, each said partial flange being connected by a fold line to said upper edge of respective said end wall panel and such fold line being substantially in alignment with said upper edge of the adjacent said side wall, each said partial flange being connected by a fold line to adjacent said side wall flange and such fold line being substantially in alignment with said side edge of adjacent said side wall.

15. In the integral blank as defined in claim 14 wherein said partial flange as measured between its said fold line connection with said side flange and the side free edge thereof and as measured parallel to said end wall panel upper ed e and said end wall panel as measured between said end wal panel side edges and as measured parallel to said end wall panel upper edge together are generally equal to or less than the distance between the side edges of said end wall whereby one of said partial flanges lie in the same plane as said end wall panel carrying said other partial flange with said plane being substantially parallel to the plane of said end wall of the erected container body. 

